Protective shock-resistant carton



L. R. DAVIS PROTECTIVE SHOCK-RESISTANT CARTON Nov. 16, 1965 3 Sheets-Sheet 1 Filed June 13, 1963 INVENTORZ LEO R. DAVIS 4W:

ATTvsJ Nov. 16, 1965 L. R. DAVIS PROTECTIVE SHOCK- fiESISTANT CARTON 3 Sheets-Sheet 2 Filed June 13, 1963 NOE INVENTOW,

R. DAVIS;

LEO

Nov. 16, 1965 L. R. DAVIS PROTECTIVE SHOCK-RESISTANT CARTON 3 Sheets-Sheet 3 Filed June 13, 19 63 FIGA. F8

FIGS. F7 F5 mvzu om LEO R. DAVIS BY WW ATTYS'II United States Patent 3,217,960 PROTECTIVE SHOCK-RESISTANT CARTGN Leo R. Davis, Exton, Pa., assignor to Downingtown Paper Company, Downingtown, Pa., a corporation of Pennsylvania Filed June 13, 1963, Ser. No. 287,625 4 Claims. (Cl. 229-39) This invention relates to a protective shock-resistant carton formed of cardboard or the like for holding electronic tubes, glass bottles and the like and has for an object the provision of improvements in this art.

One of the particular objects of the invention is to provide a carton having inner and outer rectangular tubes or sleeves in which the four corners of the inner sleeve are disposed intermediate the width of the four side panels of the outer sleeve whereby to provide an inner sleeve having approximately uniform resistance to outward movement of the packaged article at all four corners to hold the article approximately at the center of the carton for maximum protection.

Another object is to provide a double sleeve or tube type carton which can be assembled by existing conventional carton packaging machinery.

Another object is to provide a double sleeve carton which provides relatively great crushing resistance with material of relatively small caliper strength, that is, in one specific form, a very strong carton formed from relatively thin material.

Another object is to provide a double sleeve carton which maintains its shape after repeated uses, that is, after repeated insertion and removal of a packaged article.

Another object is to provide a double sleeve carton which is so formed that the inner sleeve automatically assumes its desired diagonal disposition in the outer sleeve when the carton is erected.

Another object is to provide a double sleeve carton in which the diagonally disposed inner sleeve has three parallel corner elements which frictionally engage the adjacent side panels of the outer sleeve.

Another object is to provide deep weakening, as by scoring by slitting, of certain corners of the inner sleeve to avoid objectionable spring-back action at undesired locations, this being especially useful in providing easy and correct erection of the carton.

Another object is to provide a double sleeve carton in which the inner sleeve is of such length as to overlap with a cover tuck flap of the outer sleeve and in which the inner sleeve is so formed as to provide for the easy insertion of the tuck flap without interference.

Another object is to provide a double sleeve carton which is so formed that the inner sleeve will accommodate articles of different size with approximately equal pressure upon and uniform distortion or bending of the four equalwidth side panels of the inner sleeve.

Another object is to provide a double sleeve carton which is formed of a single cardboard blank which is easy to form, assemble and print.

The above and other objects of the invention as well as various features of novelty and advantages will be apparent from the following description of an exemplary embodiment, reference being made to the accompanying drawings thereof, wherein:

FIG. 1 is a perspective side view of an erected carton, parts being broken away to show parts inside;

FIG. 2 is a plan view of the blank from which the double sleeve carton is formed;

FIG. 3 is a perspective view showing the blank in a first stage of assembling the carton;

FIG. 4 shows the blank in a second stage of assembling the carton;

3,217,960 Patented Nov. 16, 1965 'ice FIG. 5 shows the blank in a third stage of carton assembly;

FIG. 6 shows the blank after the final stage of carton assembly;

FIG. 7 is an enlarged section taken on the line 7-7 of FIG. 6;

FIG. 8 is a section like FIG. 7 but showing the carton partly erected; and

FIG. 9 is an enlarged section taken on the line 99 of FIG. 4 showing the carton fully erected.

Referring first to the cut blank shown in FIG. 2, it is seen that the blank comprises the following main panels. There are side panels P1, P2, P3 and P4 which will form an inner tube or sleeve, a connecting lap adhesive panel P5, and panels P6, P7, P8 and P9 which will form an outer tube or sleeve. The panels are connected at main fold or bend lines, there being a bend line B1 between panels P1 and P2 which is weakened against spring-back by score lines or slits 10, a bend line B2 between panels P2 and P3 which is weakened against spring-back by score lines or slits 10, a bend line B3 between panels P3 and P4 which is weakened against spring-back by score lines or slits 10, a bend line B4 between panels P4 and P5 which is line-pressed or scarfed on the outside slightly to produce line-bending; and bend lines B5, B6, B7 and B8, similar to line B4, between the panels P5 and P6, P6 and P7, P7 and P8, and P8 and P9 respectively.

The inner tube panel P1 is provided with a short narrow central fla-p F1 connected at a slightly weakened fold or bend line B9 which, in assembly, is adapted to be positioned within a cut-out opening 11 in panel P5 to receive adhesive to hold the flap F1 and panel P1 in place. The fiap F1 has a small projection or tab Fla which prevents the flap from being pushed through its opening during bending in assembling the carton.

The panel P3 is provided with an integral stiif starting flap F2 which aids in erection of the carton, as will be described. On the other side the panel. P3 is provided with a larger integral stiff flap F3 which aids in centering the inner tube in the erection of the carton. The flap F3 has inclined side edges 12 to leave the panel P4, out of which the flap F3 is cut, as strong as possible.

At the ends of the bend line B2 the panels P2 and P3 are conjointly cut to form end openings or recesses 13 which aid the insertion of a cover tuck flap in the erection of the carton, as will be described.

The panel P6 is provided at its ends with end closure flaps F5 and F6 bendable about weakened lines B10 and B11 respectively.

The panel P7 at one end is provided with an end closure flap F7 having a tuck tab or fiap F7a bendable about weakened fold lines B12 and B13 respectively.

The panel PS has end flaps F6 and F9 bendable about weakened fold lines B14 and B15 respectively.

The panel P9 at one end is provided wlth an end closure flap Flt) having a tuck tab or flap Flt a bendable about weakened fold lines B17 and B18 respect1vely.

The first step in assembling the carton, as shown in FIG. 3, is to fold along the line B2 to bring panels P1 and P2 down over panels P4 and P3, respectively, with flap F1 disposed in the opening 11 of panel P5. Flap F2 is left projecting rearwardly from panel P3.

The second step in assembling the carton, as shown in FIG. 4, is to fold along the line B4 to bring panels P1 and P2 down against the inside surfaces of panels P5 and P6, with panels P4 and P3 disposed above the panels P1 and P2 respectively. Panel-s P1 and P2, being covered by panels P4 and P3, cannot be seen in FIG. 4.

The third step, as shown in FIG. 5, is to fold along the line B6 (or to turn the blank over) and apply adhesive 15, indicated by stippling, to the outer surf-ace of the panel P and to the inner surface of the flap F1, the flap F1 being pushed into generally coplanar position with the panel P5 to receive glue by bending the small tab Fla.

The final step in assembling the carton, as shown in FIG. 6, is to fold the end panel P? down over the panel P8 and the glued panel P5 and flap F1 and to secure the glued surfaces together.

The carton at this point is complete insofar as manufacture is concerned and can be shipped out for use. It is shown in FIG. 7 in section and in somewhat open condition for clarity. The operations up to this point have been referred to as assembly operations to distinguish from subsequent operations in use which will be referred to as erection operations. The invention contributes important points of novelty and advantages as to both the assembly and erection operations.

One stage of erection is shown in FIG. 8. Here the inner tube or sleeve, which is referred to as a whole by the designation TI, and the outer tube T2 are being opened by pressure on the diagonal corners or fold lines B6 and B8. The inner tube T1 is attached to the outer tube T2 only at one corner, which is the fold lines B4 and B9 at the mid-Width of panel P9 but is free at the other three corners. The flap F2 holds the corner B2 away from the corner B6 initially and thereby avoids the possibility that the panels P3 and P4 will bend the wrong way at the line B3. The corner B1 rubs along the panel P6 and causes the flap F3 to ride along and down the side P8 until it bends and its end stops in the corner B8, as shown in FIG. 9.

In the final erected position shown in FIG. 9 the inner tube T1 stands in an almost central position on a diagonal to the outer tube T2 with its corners directed approximately to the center of Width of the side panels of the outer tube. The corner B1 is in direct frictional engagement with the side panel P6. The flap F2 holds the corner B2 away slightly but with frictional engagement at the corner B2 with the side panel P7. And the corner B3 through the flap F3 maintains frictional engagement with the side panel P8.

The four sides P1, P2, P3, P4 of the inner tube T1, as illustrated, are of equal width and when an article A, shown in broken lines in FIG. 9, is placed in the inner tube it engages the mid-width of the side panels. There is therefore an approximately equal force at all corners tending to hold the article centered for best protection (away from the outer tube walls). Moreover the evencentered engagement of the article with the side panels of the inner sleeve or tube provides the maximum range in diameter of articles to be inserted, while in all cases holding the-m properly centered.

At the bottom left portion of FIG. 1 it is shown how the tuck flap Fltla is allowed to enter by reason of the recess 13 at the corner B2. The closure flap F7 is hinged on the opposite side and its tuck flap F7a is too short to need the recess 13 at the other end of the tube but in those cases Where it is hinged on the other side and its tuck fiap is longer, the clearance recess 13 at this end will be utilized.

The lines of deep weakening B1, B2 and B3 allow the inner tube to be easily bent to shape without spring-back.

From FIG. 7 it can be seen that the carton, in folded condition, has the upper panel P3 of the inner sleeve in such disposition that the flap F2 of that panel or side is directed toward the corner B6 of the outer sleeve which is disposed diagonally opposite the corner B8 of the outer sleeve which is located adjacent and beyond the panelconnected corner B4, B9 of the inner sleeve; also that the end of the flap F2 almost engages within the adjacent diagonal corner B6. Stated another way, the inner sleeve, considered in flat-folded condition, has parts which extend from the panel-connected corner B4, B9 of the inner sleeve at the mid-width of the outer sleeve panel P9 to the diagonally opposite corner B6 of the outer sleeve. This assures the proper opening of the inner sleeve by the action of the rigid extending flap F2, as previously explained. The term rigid here means, of course, that the fi-ap and its integral connection with its panel are as rigid as the original cardboard material and that there are no weakened lines. Actually, both the flap F2 and the flap F3 are resilient and will bend somewhat in erection, as shown in FIG. 9.

Both the inner sleeve and the outer sleeve are complete enclosures in that their end panels P1; and P9 are connected to other panels to form fully connected tubes.

It is thus seen that the invention provides an improved collapsible double sleeve carton which is easy to manufacture, assemble and erect; which is economical of material used; which is economic-a1 of labor and operations; which fully protects the enclosed article; which will readily take and center articles of different diameters; which can be re-used repeatedly; and which is a general improvement in the art.

While one embodiment of the invention has been described for purposes of illustration, it is to be understood that there may be various embodiments and modifications within the general scope of the invention.

I claim:

1. A shock resistant collapsible cardboard carton, comprising in combination,

a single integral blank comprising,

a first panel,

a first short narrow connection flap connected by a *weakened bend line to said first panel,

a small tab extension on the outer edge of said first a second panel connected to said first panel by a deepweakened first corner bend line,

a third panel connected to said second panel by a deepweakened second corner bend line,

said second and third panels having between them a recess at the end of said second corner bend line, said third panel having a second integral rigid medial flap cut out of said second panel,

a fourth panel connected to said third panel by a deepweakened third corner bend line,

said third panel having a third integral rigid medial flap cut out of said fourth panel,

a fifth connection panel connected to said fourth panel by a lightly weakened fourth corner bend line, said fifth panel having an opening cut therein of a size to receive said first fiap but not its end edge tab,

a sixth panel connected to said fifth panel by a lightly weakened fifth corner bend line,

said sixth panel having fifth and sixth flaps at the end to serve for end closure,

a seventh panel connected to said sixth panel by a lightly weakened sixth corner bend line,

said seventh panel having a seventh fiap with a tuck flap on one end thereof to serve for end closure,

an eighth panel connected to the seventh panel by a lightly weakened seventh corner bend line,

said eighth panel having eighth and ninth flaps on the ends thereof to serve for end closure,

and a ninth panel connected to the eighth panel by a lightly weakened eighth corner bend line,

said ninth panel having a tenth flap with a tuck flap on one end thereof to serve for end closure,

in assembly said first flap being brought into the opening of said fifth panel,

and the fifth panel and said first flap being secured to the ninth panel from the end edge inward to constitute fully closed outer and inner sleeves, the first flap being secured to the ninth panel in a position to secure a corner of the inner sleeve to the midwidth of the ninth panel,

the inner sleeve being formed by said first, second, third and fourth panels,

the outer sleeve being formed by said sixth, seventh,

eighth and ninth panels,

the second flap, in folded condition, extending substantially to said sixth fold line which is the diagonal corner of the outer sleeve opposite the panel-connected corner of the inner sleeve,

and said second and third flaps, when the carton is erected, frictionally engaging the seventh and eighth panels respectively to hold said first corner against said sixth panel.

2. A carton as set forth in claim 1,

in which the outer and inner sleeves, when the carton is erected, have approximately equilateral sides and equal corner angles,

and in which the corners of the inner sleeve are located approximately at the mid-width of the side panels of the outer sleeve.

3. A shock resistant collapsible carton, comprising in combination:

a series of integrally connected panels, forming when the carton is erected,

an outer rectangular sleeve having opposite equal Width panels and opposite equal corner angles,

and an inner rectangular sleeve having opposite equal Width panels and opposite equal corner angles,

both the inner sleeve and the outer sleeve being formed as a completely closed unit,

the inner sleeve being connected at one corner to a side panel of the outer sleeve adjacent the midpoint of said outer sleeve side panel,

the other three corners of the inner sleeve being located adjacent the midpoint of the respective side panels of the outer sleeve and having free movement relative to said side panels of the outer sleeve.

two adjacent corners of said inner sleeve having resilient projecting flaps engaging the: adjacent side panels of said outer sleeve when said carton is in its erected position, one of said resilient projecting flaps being on the corner diagonally opposite the said one corner of said inner sleeve where the inner sleeve is connected to the side panel of the outer sleeve,

and said inner panel and the said one resilient flap extending from said panel connected corner of the inner sleeve to the diagonally opposite corner of said outer sleeve when said carton is folded fiat so that said one flap extends into said diagonal corner of said outer sleeve to cause the inner sleeve to open when said outer sleeve is opened during erection of the carton.

4. A shock resistant collapsible carton as set forth in claim 3 in which said resilient projecting flaps are formed integrally with and extend from opposite: side edges of the panel of said inner sleeve and the resilient flap oppo site said one resilient flap extends into a corner of said outer sleeve when said carton is erected.

References (Iited by the Examiner UNITED STATES PATENTS 2,714,981 8/1955 Leavens.

2,732,122 1/1956 Bolding 22914 X 2,732,996 1/1956 Psantalone 229-14 X 2,764,337 9/1956 Bolding 229-14 X 2,808,193 10/ 1957 Michalka.

2,828,902 4/1958 Ringler 229-14 2,997,220 8/1961 Williamson 229-14 3,059,830 10/1962 Kramer W 229-39 FRANKLIN T. GARRETT, Primary Examiner. 

1. A SHOCK RESISTANT COLLAPSIBLE CARDBOARD CARTON, COMPRISING IN COMBINATION, A SINGLE INTEGRAL BLANK COMPRISING, A FIRST PANEL, A FIRST SHORT NARROW CONNECTION FLAP CONNECTED BY A WEAKENED BEND LINE TO SAID FIRST PANEL, A SMALL TAB EXTENSION ON THE OUTER EDGE OF SAID FIRST FLAP, A SECOND PANEL CONNECTED TO SAID FIRST PANEL BY A DEEPWEAKENED FIRST CORNER BEND LINE, A THIRD PANEL CONNECTED TO SAID SECOND PANEL BY A DEEPWEAKENED SECOND CORNER BEND LINE, SAID SECOND AND THIRD PANELS HAVING BETWEEN THEM A RECESS AT THE END OF SAID SECOND CORNER BEND LINE, SAID THIRD PANEL HAVING A SECOND INTEGRAL RIGID MEDIAL FLAP CUT OUT OF SAID SECOND PANEL, A FOURTH PANEL CONNECTED TO SAID THIRD PANEL BY A DEEPWEAKENED THIRD CORNER BEND LINE, SAID THIRD PANEL HAVING A THIRD INTEGRAL RIGID MEDIAL FLAP CUT OUT OF SAID FOURTH PANEL, A FIFTH CONNECTION PANEL CONNECTED TO SAID FOURTH PANEL BY A LIGHTLY WEAKENED FOURTH CORNER BEND LINE, SAID FIFTH PANEL HAVING AN OPENING CUT THEREIN OF A SIZE TO RECEIVE SAID FIRST FLAP BUT NOT ITS END EDGE TAB, A SIXTH PANEL CONNECTED TO SAID FIFTH PANEL BY A LIGHTLY WEAKENED FIFTH CORNER BEND LINE, SAID SIXTH PANEL HAVING FIFTH AND SIXTH FLAPS AT THE END TO SERVE FOR END CLOSURE, A SEVENTH PANEL CONNECTED TO SAID SIXTH PANEL BY A LIGHTLY WEAKENED SIXTH CORNER BEND LINE, SAID SEVENTH PANEL HAVING A SEVENTH FLAP WITH A TUCK FLAP ON ONE END THEREOF TO SERVE FOR END CLOSURE, AN EIGHTE PANEL CONNECTED TO THE SEVENTH PANEL BY A LIGHTLY WEAKENED SEVENTH CORNER BEND LINE, SAID EIGHTH PANEL HAVING EIGHTH AND NINTH FLAPS ON THE ENDS THEREOF TO SERVE FOR END CLOSURE, AND A NINTH PANEL CONNECTED TO THE EIGHTH PANEL BY A LIGHTLY WEAKENED EIGHTH CORNER BEND LINE, SAID NINTH PANEL HAVING A TENTH FLAP WITH A TUCK FLAP ON ONE END THEREOF TO SERVE FOR END CLOSURE, IN ASSEMBLY SAID FIRST FLAP BEING BROUGHT INTO THE OPENING OF SAID FIFTH PANEL, AND THE FIFTH PANEL AND SAID FIRST FLAP BEING SECURED TO THE NINTH PANEL FROM THE END EDGE INWARD TO CONSTITUTE FULLY CLOSED OUTER AND INNER SLEEVES, THE FIRST FLAP BEING SECURED TO THE NINTH PANEL IN A POSITION TO SECURE A CORNER FO THE INNER SLEEVE TO THE MIDWIDTH OF THE NINTH PANEL, THE INNER SLEEVE BEING FORMED BY SAID FIRST, SECOND, THIRD AND FOURTH PANELS, THE OUTER SLEEVE BEING FORMED BY SAID SIXTH, SEVENTH, EIGHTH AND NINTH PANELS, THE SECOND FLAP, IN FOLDED CONDITION, EXTENDING SUBSTANTIALLY TO SAID SIXTH FOLD LINE WHICH IS THE DIAGONAL CORNER OF THE OUTER SLEEVE OPPOSITE THE PANEL-CONNECTED CORNER OF THE INNER SLEEVE, AND SAID SECOND AND THIRD FLAPS, WHEN THE CARTON IS ERECTED, FRICTIONALLY ENGAGING THE SEVENTH AND EIGHTH PANELS RESPECTIVELY TO HOLD SAID FIRST CORNER AGANIST SAID SIXTH PANEL. 